Automotive vehicle seat insert

ABSTRACT

There is disclosed an insert suitable for placement within a seat of an automotive vehicle. The insert preferably includes multiple layers, one of which includes a heater for providing an occupant of the seat with warmth. The insert also preferably includes a blower or air pump for providing ventilation and/or cooling to the seat occupant.

CLAIM OF PRIORITY

To the extent applicable, the present invention claims the benefit ofthe priority of U.S. Provisional Application Ser. No. 60/393,815, filedJul. 3, 2002 and U.S. Provisional Application Ser. No. 60/433,270, filedDec. 13, 2002, both of which are incorporated herein by reference forall purposes.

FIELD OF THE INVENTION

The present invention relates generally to automotive vehicle seats, andmore particularly to an insert for providing heating, cooling,ventilation or a combination thereof to a seat of an automotive vehicle.

BACKGROUND OF THE INVENTION

For many years the transportation industry has been concerned withdesigning seats for automotive vehicles that provide added comfort tooccupants in the seats. Various innovations in providing seating comfortare discussed in U.S. Pat. Nos. 6,064,037; 5,921,314; 5,403,065;6,048,024 and 6,003,950, all of which are expressly incorporated hereinby reference for all purposes. In addition, other innovations inproviding seating comfort are discussed in U.S. patent application Ser.No. 09/619,171, filed Jul. 19, 2000, titled “Ventilated Seat Having aPad Assembly and a Distribution Device”; U.S. patent application Ser.No. 09/755,505, filed Jan. 5, 2001, titled “Ventilated Seat”; and U.S.patent application Ser. No. 09/755,506, filed Jan. 5, 2001, titled“Portable Ventilated Seat”, each of which are expressly incorporatedherein by reference for all purposes. In the interest of continuing suchinnovation, the present invention provides an improved seating system,insert for a seat or both, which are preferably suitable for employmentwithin or as part of an automotive vehicle seat and which assist inproviding comfort control to an occupant in the seat.

SUMMARY OF THE INVENTION

According to the present invention, there is disclosed a seat insert, amethod of forming the seat insert and a ventilated seat that ispreferably suitable for an automotive vehicle. The insert preferablyincludes a forward layer, a rearward layer and a middle layer, althoughgreater or fewer layers may be included. When included, the forwardlayer typically includes a first barrier sub-layer, a heater sub-layer,a plurality of openings or a combination thereof. In preferredembodiments, the first barrier sub-layer is formed of a plasticmaterial, the heater sub-layer is formed as a lay-wire heater or both.

The rearward layer, when included, has a second barrier sub-layer, anopening or both. In a preferred embodiment, the second barrier sub-layeris formed of a plastic material like the first barrier sub-layer. Themiddle layer typically includes a spacer sub-layer defining an openspace. In a preferred embodiment, the spacer sub-layer is formed ofinterwoven polymeric strand material. An air mover (e.g., a blower) isattached to the insert and is preferably at least partially disposedwithin the at least one opening of the rearward layer, although notrequired. The air mover is in fluid communication with the plurality ofopenings in the forward layer, the open space of the spacer sub-layer orboth.

During formation of the insert, the first barrier sub-layer ispreferably sealingly attached to the second barrier sub-layer about aperiphery of the insert, although other attachments may be employed. Theblower is preferably configured to pull air through the plurality ofopenings in the forward layer and through the open space of the spacersub-layer, but it may also push air through these areas.

When assembled to a seat (e.g., a vehicle seat), the seat preferablyincludes a seat cushion component and a seat backrest component. Atleast one of the components is typically ventilated by the insert andeach ventilated component typically includes an air-permeable trimsurface at occupant contact areas of the seat. The insert is preferablylocated beneath the trim surface of each ventilated component.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and inventive aspects of the present invention will becomemore apparent upon reading the following detailed description, claimsand drawings, of which the following is a brief description:

FIG. 1 is a blown up perspective view of a seat insert in accordancewith an exemplary aspect of the present invention;

FIG. 2 is a flow diagram for producing seat inserts in accordance withan exemplary aspect of the present invention;

FIG. 3 is a partially cut-away elevational view of the seat insert ofFIG. 1 after assembly of the insert;

FIG. 4 is a sectional view of the insert of FIGS. 1 and 3 taken alongline 4-4 in FIG. 3;

FIG. 5 is a perspective view of an exemplary blower suitable forapplication in the insert of the present invention; and

FIG. 6 is a sectional view of the insert attached in an exemplary mannerto a seat of an automotive vehicle according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is predicated upon providing an insert suitablefor placement within an automotive vehicle seat to provide heating,cooling, ventilation or a combination thereof to an occupant in theseat. The insert will include at least one layer, but preferablyincludes multiple (e.g., three) layers and each of the layers mayinclude one or more sub-layers. For example, one of the layerspreferably incorporates a heater or heater sub-layer into the insert.One or more of the layers also preferably incorporates a plastic filmsub-layer for assisting in lamination of the layers, for providing a gasbarrier or both. It is also preferable for one or more of the layers toprovide a spacer sub-layer for providing open space within the insert.Additionally, a blower may be incorporated into the insert for providingfluid flow through the insert.

Referring to FIGS. 1 and 3-5, there is illustrated an exemplary insert10 suitable for placement within a seat of an automotive vehicle. Theinsert 10 preferably includes a plurality of layers that may be separatebut are preferably attached to each other to form the insert. In theembodiment shown, the insert 10 includes a first or forward layer 14(e.g., the layer of the insert configured to be closest an occupant ofthe seat), a second or middle layer 16 and a third or rearward layer 20(e.g., the layer of the insert configured to be furthest from theoccupant of the seat).

It is preferred that one of the layers 14, 16, 20 includes a heater. Inthe embodiment depicted, the forward layer 14 includes a heatersub-layer 26, which is preferably laminated to a gas barrier sub-layer28 (e.g., a film, a textile or otherwise) although such film is notnecessarily required. Various different types of heaters are suitablefor incorporation into a car seat and it is contemplated that any ofsuch heaters may be incorporated into the insert 10 of the presentinvention. Such heaters typically incorporate flexible electricalheating elements that are preferably thin, flat, non-obtrusive or acombination thereof. As examples, a lay-wire heater, a carbon fiberheater, a positive thermal coefficient (PTC) heater, a thermoelectricheater or the like, which are typically supported with a backing (e.g.,a cloth or fabric type backing) may be used within the insert. In apreferred embodiment, the heater sub-layer 26 is a carbon fiber typeheater with a backing (e.g., a nonwoven layer). One exemplary preferredheater is sold under the tradename CARBOTEX® and commercially availablefrom W.E.T Automotive Systems, Inc. in Germany and/or FTG Fraser-TechnikGmbH, Schleizer Strasse 56-58, D-95028 Hot/Saale, Germany. An example ofsuch a heater is disclosed in U.S. Pat. No. 6,064,037, issued May 16,2000, herein expressly incorporated by reference for all puposes.

When included, the barrier sub-layer 28 is typically formed of a plasticor polymeric material that softens or melts upon exposure to heat toassist the sub-layer 28 to adhere to one or more other layers orsub-layers. Alternatively, the barrier sub-layer 28 may be formed offabrics, woven materials (e.g, goretex or microfibers), nylon, closedpore foam or other materials. Preferably, the barrier sub-layer 28 issubstantially impermeable to fluids and particularly air such that thesub-layer 28 can assist in forming an air barrier as will be describedfurther herein. Dimensionally, for a film barrier sub-layer, it ispreferable for the film thickness to be about 0.1 mm to about 2.0 mmthick and more preferably about 0.7 mm to about 1.0 mm thick. Of course,it is contemplated that the film sub-layer 28 may have a variablethickness and may be outside of the aforementioned ranges.

The first layer 14 may also include one or more buffer sub-layers, oneor more adhesives or adhesive sub-layers, one or more tape sub-layers,one or more porous foam layers or a combination thereof. Adhesive may besupplied in layers, drops or in a variety of other configurations.Preferably, the buffer layer is at least partially formed of aninsulating material.

In the preferred embodiment depicted, the first layer 14 includes twoadhesive sub-layers 34, one strip of tape 36 and one buffer sub-layer38. The adhesive sub-layers 34 are preferably formed of a hot meltadhesive although not necessarily required. The adhesive may be providedas a web or otherwise and may be continuous or non continuous (e.g., maybe applied in drops, dabs or the like). The adhesive sub-layers mayinclude polyamides, polyesters, elastomers, urethanes, olefin polymersor a combination thereof. Moreover, the adhesives may be formulated asdesired for particular processing parameters or conditions. Preferably,the adhesive sub-layers are substantially free of anti-blockingsolutions, blowing additives, process contaminants or the like whichmight interfere with adhesive performance. As an example, one suitablehot melt adhesive is commercially available as a non-woven web under thetradename SPUNFAB® from Spunfab, Ltd. 175 Muffin Lane, Cuyahoga Falls,Ohio 44223.

The buffer sub-layer 38 in the embodiment depicted is a layer of gauzewhich is capable of protecting the heater layer 20 although variousalternative protective materials may be used such as cloth, fleece orthe like. The tape 36 is preferably tacky on two sides.

According to an alternative embodiment, it is contemplated that thefirst layer 14 may also include an air-permeable layer (not shown)between buffer sub-layer 38 and an occupant of the seat. Theair-permeable layer, which may be any one of a variety of air-permeablematerials (such as reticulated foam, for example) may be able to helpdistribute air under the occupant.

One of the layers 14, 16, 20, preferably the middle layer 16, includes aspacer sub-layer 48 formed of a spacer material. The spacer material maybe provided as a variety of synthetic materials such as plastic orpolymeric materials, padding and stuffing materials, lining and carriermaterials or the like. Preferably, the spacer material creates asub-layer 48 that functionally provides open space within the sub-layerwhile remaining at least partially pliable or flexible between the firstand third layers 14, 20. As one example, the spacer sub-layer may beprovided as a plurality of rubber, foam plastic or other members orfibers. The members or fibers are preferably spaced apart from eachother to provide open space therebetween while still being close enoughtogether to provide cushion and support. As another example the spacersub-layer 48 may be formed of a 3-dimensional spacer fabric structure ormaterial.

In the preferred embodiment depicted, the middle layer 16 includes onlythe spacer sub-layer 48, however, it is contemplated that additionalsub-layers (e.g., adhesive sub-layers) or other materials (e.g.,adhesives) may be incorporated into the middle layer 16. The particularsub-layer 48 shown is formed of polymeric (e.g., polyester) strandmaterial that is interwoven to provide opposing honeycomb structures 56(e.g., fabric panels), which are interconnected by several additionalpolymeric strand materials to provide open space 58 between thestructures 56 while still providing cushion and support. As an example,one preferred material is sold under the tradename 3MESH® and iscommercially available from Müller Textil GmbH, Germany or MüllerTextiles, Inc., Rhode Island, USA.

In another of the layers 14, 16, 20 of the insert 10, preferably therearward layer 20, there is included an outer protective or buffersub-layer and another barrier sub-layer. In the embodiment shown, oneintegrated sub-layer 62 provides the both the barrier sub-layer 66 andthe outer protective sub-layer 68 although they may be providedseparately. The barrier sub-layer 66 for the rearward layer 20 may bethe same or different than the barrier sub-layer 28 of the forward layer14.

Preferably, the protective sub-layer 68 is formed of a fleece material,however, various other materials may be used such as gauze, cloth,fabric or the like. It is also preferable for the rearward layer 20 toinclude an adhesive or adhesive sub-layer 70 similar to or the same asthose discussed in relation to the forward layer 14. According to apreferred embodiment, the adhesive sub-layer 70 is provided integrallywith the integrated sub-layer 62.

In a highly preferred embodiment, an attachment component 72 is includedin one of the layers 14, 16, 20. The attachment component 72 shown inFIG. 1 is a frame member that preferably defines an opening orthrough-hole 74. It is contemplated that the frame member may be in avariety of configurations (e.g., annular, rectangular, square, geometricor otherwise) and may be formed of a variety of preferably rigid orsemi-rigid materials (metal, plastic or the like).

Notably, several of the materials of the various layers and sub-layersof the insert 10 may be environmentally friendly. For example, andwithout limitation, the materials of the spacer sub-layer 48, the bufferand protective sub-layers 38, 68 and the barrier sub-layers 28, 66 maybe recyclable.

Assembly

Generally, for forming a vehicle seat insert according to the presentinvention, it is contemplated that the various layers and sub-layers ofthe insert as described above may be combined in a variety of sequencesand according to a variety of protocols and technique. Thus, the orderin which the various layers and sub-layers are combined and thetechniques of combining should not in any way limit the presentinvention unless such order or techniques is specifically claimed.Moreover, it is also contemplated that there may be greater or fewerlayers and that each layer may include greater or fewer sub-layers.

According to a preferred method, the sub-layers of the front or firstlayer and the third or rearward layer are each laminated separatelyfollowed by laminating the front layer to the rearward layer with themiddle layer in between. Referring to FIGS. 1 and 2, the first layer 14is formed according to a preferred method by feeding the varioussub-layers 38, 26, 28 to a laminator 80 (e.g., a belt and rollerlaminator).

Although the manner in which the sub-layers 38, 26, 28 are fed to thelaminator 80 may be varied, the preferred embodiment has the buffersub-layer 38 and one of the adhesive sub-layers 34 as the outersub-layers on the outer sides of the first layer 14. The barriersub-layer 28 and the heater sub-layer 26 are directly inside of theouter sub-layers and, as shown, the other adhesive sub-layer 34 isbetween the barrier sub-layer 28 and the heater sub-layer 26.Preferably, the tape 36 is integrated into the first layer 14 betweenthe buffer sub-layer 38 and the heater sub-layer 26 such that the tape36 may be used to form a pocket for securing a wire harness 40 to theinsert 10. It is also preferable for some amount of adhesive to beapplied between and adhere the buffer sub-layer 38 and the heatersub-layer 26 to each other.

During the lamination process, it may be preferable for the laminator 80to expose various portions of the first layer 14 to differenttemperatures. For the embodiment illustrated, it is preferred that thelaminator 80 expose a first side of the first layer 14 (e.g., the sidethat includes the buffer sub-layer 38 and the heater 26) to a highertemperature while exposing a second opposite side of the first layer 14(e.g., the side having the film sub-layer 28 and outermost adhesivesub-layer 34) to a lower temperature. Depending upon the materials used,the difference between the higher and lower temperatures is preferablybetween about 5° C. and about 150° C., more preferably between about 10°C. and about 100° C. and even more preferably between about 20° C. and80° C. In this manner, the central adhesive sub-layer 34 of the firstlayer 14 is exposed to higher temperatures and is induced to moresubstantially melt and adhere the barrier sub-layer 28 to the heatersub-layer 26. At the same time, the outermost adhesive sub-layer 34 ofthe first layer 14 is maintained at a lower temperature than the centraladhesive sub-layer 34 thereby avoiding excess melting of the outermostadhesive sub-layer 34.

The sub-layers 36, 26, 28 are preferably fed to the laminator 80 fromrolls or otherwise and are cut to shape to form the first layer 14 afterlamination. The first layer 14 may be cut to nearly any desired shape orconfiguration. In the illustrated embodiment, the first layer 14 is cutto be generally rectangular and to include an extension 84 and aplurality of through-holes 86. In FIG. 1, the through-holes 86 arearranged in a generally rectangular configuration and are eachsubstantially the same size. In FIG. 3, however, the through-holes 86are shown in a preferred configuration as progressively becoming largerfrom one side of the insert 10 to another.

Referring to FIG. 3, the through-holes 86 preferably increase in size asthe distance of the holes from the blower increases. This increase insize provides a more uniform flow of air throughout the insert 10. It isbelieved that the increase in the total cross-sectional area ofthrough-holes 86 as the distance from the blower increases allows air toenter or exit the openings at a more uniform rate than if thecross-sectional areas of through-holes at different distances from theblower were equal. The increase in cross-sectional area can be achievedby increasing the size of the holes, the number of holes, or acombination thereof. Finally, the increase in the cross-sectional areaneed not be a strict progression for each and every through-hole,rather, the through-holes in a region further from the blower shouldhave a greater cross-sectional area than the through-holes in a regioncloser to the blower. Through-holes 86 may also be provided in a varietyof different patterns. According to one preferred embodiment,through-holes 86 are provided in a substantially “U” shapedconfiguration corresponding to the legs and seat of the occupant.According to an alternative embodiment, through-holes 86 may be providedin a linear or straight line pattern (for example, to correspond to theback of an occupant) or in a variety of other patterns. Such pattern maybe influenced by the portion of the seat in which the insert is used andthe portion of the body of the occupant nearest the insert. According toother alternative embodiments, the number, size, shape, and pattern ofthrough-holes 86 may vary.

The rearward layer 20, like the front layer 14, is also preferablyformed by attaching it sub-layers 62, 70 in a lamination process.Referring again to FIGS. 1 and 2, the barrier sub-layer 66, theprotective sub-layer 68 and the adhesive sub-layer 70 are fed to alaminator 90 (e.g., a belt laminator) such that the barrier sub-layer 66is between and attached to the adhesive sub-layer 70 and the protectivesub-layer 68. Thereafter, the rearward layer 20 is cut to have a shapesubstantially corresponding to the first layer 14. Of course, it iscontemplated that the rearward layer may be cut into a variety of otherconfigurations as well. Preferably, the rearward layer 20 includes athrough-hole 98 as shown in FIG. 3 through an extension 100 of therearward layer 20 that corresponds to the extension 84 of the firstlayer 14. It is contemplated, however, that the through-hole 98 may alsobe formed in the forward layer 14 if desired.

Once the middle layer 16 has been appropriately cut or otherwise shapedto the proper configuration, which preferably corresponds to the forwardand rearward layers 14, 20, each of the layers 14, 16, 20 are laminatedtogether to attach the layers 14, 16, 20 to each other. As shown, themiddle layer 16 may be cut to include an extension 96 corresponding tothe extensions 84, 100.

In the preferred embodiment, the layers 14, 16, 20 are laminated in astationary lamination device 104 at elevated temperatures such that theadhesive sub-layer 70 of the rearward layer 20 and the outermostadhesive sub-layer 34 of the forward layer 14 both adhere and attach theforward layer 14 and the rearward layer 20 to the middle layer 16 (e.g.,the honeycomb structure). At the same time, it is preferred that thebarrier sub-layer 28 of the front layer 14 and the barrier sub-layer 66of the rearward layer 20 be adhered to one another about an outerperipheral strip 106 of the insert 10. It is also preferred that theattachment component 72 be sandwiched and attached between at leastportion of the rearward layer 20 and the middle layer 16 although theattachment component may be otherwise attached (e.g., retrofit,fastened, or the like).

The strip 106 may have a width as high as four (4) centimeters orgreater. Preferably, the strip is between about 0.2 cm and about 3 cmand more preferably between about 1.0 cm and 2.0 cm. Advantageously, theadhesive sub-layers 34, 70 and the outer laminated peripheral strip 106separately and together assist in forming the insert 10 as a tightlyintegrated unit wherein the layers 14, 16, 20 are substantially immobilerelative to each other.

While pre-cutting the layers 14, 16, 20 followed by laminating theperipheral edges of at least two of the layers 14, 20 have beendiscussed, it is contemplated that cutting of the layers 14, 16, 20 andlaminating of the layers may be integrated into a single processingstep. For example, it is contemplated that supplies (e.g., rolls) ofeach of the layers 14, 16, 20 may be provided to a machine thatlaminates outer edges of each of the layers 14, 16, 20 together forforming the peripheral strip 106 as the supplies continuously orintermittently provide the layer 14, 16, 20 to the machine. Thus,inserts 10 may be formed by cutting the inserts 10 with the peripheralstrip 106 from the laminated layers 14, 16, 20 and such cutting may beperformed by the laminating machine or by another cutting machine ordevice. In such an embodiment, it is contemplated that the through-holesin the forward layer 14 and the through-hole in the rearward layer maybe formed prior to, during or after lamination forming the outerperipheral strip 106.

Although laminating the edges of the film together and the use ofadhesive layers have been found particularly advantageous, it iscontemplated that other methods of attachment may also be employed inconjunction with the laminated edges or separately. For example a robotmay be employed to apply a variety of adhesives such as hot-melt, heatactivated, encapsulated or other types of adhesives. In one preferredalternative, an encapsulated adhesive may be applied to a first layerfollowed by breaking the encapsulated adhesive in close time proximityto attaching a second layer to the first layer. In other preferredembodiments, it is contemplated that the plastic films may be fusedtogether with other techniques such as those used for book binding.Moreover, mechanical attachments (e.g., snaps, zippers, sewing,stitching, stapling or the like) may be used alone or in conjunctionwith the plastic films and adhesives.

During final assembly 110, the wire harness 40 is preferably insertedwithin the pocket formed by the tape 36 or otherwise attached to theinsert 10. Also, a blower, the housing 120 of which is shown in FIG. 5,is preferably attached to the attachment component 72 of the insert 10.In the embodiment shown, the housing 120 include flanges 124 suitablefor snap-fitting the housing 120 to the attachment component 72. In thismanner, the blower can be attached to the rest of the insert 10 and canbe placed in fluid communication with the through-holes 86 of the firstlayer 14, the open space 58 of the middle layer 16 and the through-hole98 of the rearward layer 20. Advantageously, the attachment component 72and flanges 124 provide a unique and efficient method of attaching theblower to the insert 10. It is contemplated however, that various othermethods of attachment (e.g., fasteners, sewing, mating threadedattachments, quick connects or the like) may be used to attach theblower to the insert 10. It is also contemplated that the attachmentcomponent 72 and the housing 120 and flanges 124 of the blower may bevaried within the scope of the present invention.

For assembly of the insert 10 to a vehicle seat (not shown), the insert10 is preferably connected (e.g., sewn, adhered or otherwise attached)to a portion of the seat such as the cover (e.g., a perforated leathercover) or to a cushion (e.g., foam) of the seat. In one preferredembodiment, a seat cover may be configured to include a pocket forreceiving the insert 10. Alternatively, it is contemplated that hook andloop fasteners may be utilized to attach the insert 10 to portions(e.g., the cover or foam) of the seat.

The insert 10 is preferably positioned in the seat such that the firstlayer 14 is closer to the outer seat cover relative to the rearwardlayer 20 although not necessarily required. It is also preferable for anextension 139 formed by the extensions 84, 96, 100 of the layers 14, 20to extend behind the cushion of the seat such that the blower may beattached to a portion of the frame of the vehicle seat. Preferably, theextension 139 is a tubular structure for providing fluid communicationbetween the open space of the spacer layer 48 and the blower.Additionally, the wire harness 40, the heater sublayer 26, the blower ora combination thereof are preferably connected in signalingcommunication with a control unit 130 and/or each other. The controlunit 130 may be separate from or integrated into the vehicle.

In one embodiment referring to FIGS. 3, 4 and 6, the insert 10 is formedwith one or more (e.g., three) through-holes 140 that extend through thelayers, sub-layers or both of the insert 10 such that the through-holes140 extend entirely or substantially entirely through the insert 10.Preferably, the insert 10 (e.g., the barrier layers 28, 66) have a seal141 about the through-holes 140 for substantially preventing directfluid communication between the through-holes 140 and the open space 58within the insert 10. In the embodiment depicted, the barrier sub-layers28, 66 are attached to each other during the lamination process to forma substantially air-tight seal 141 about the through-holes 140.

Advantageously, the through-holes 140 can assist in the assembly of theinsert 10 and/or a seat cover 142 to a seat 144 of an automotivevehicle. As shown, for each through-hole 140, a portion 148 (e.g., acushion layer, a felt layer, a leather layer, combinations thereof orthe like) of the seat cover 142 is extended through the through-hole 140and is attached to foam 154 of the seat 144. In the embodiment depicted,the portion 148 is attached to the foam 154 by wrapping or otherwiseattaching the portion 148 about a member 162 (e.g., a bar or wire) thatis attached to (e.g., at least partially imbedded within) the foam 154.Additionally, one or more loops 166 (e.g., metal loops) are integratedwith the portion 148 and are looped about the member 162 for assistingin attaching the portion 148 to the member 162.

It shall be appreciated that, in embodiments alternative to the onedepicted, a variety of materials or members such as wire, thread,stitches, fasteners, foam or the like may extend through thethrough-holes 140 in the insert 10 for assisting in the attachment ofthe seat cover 142, the insert 10 or both to the other components of theseat 144. Moreover the materials or members may be connected to the seatcover, the foam, the seat frame, other portions of the seat or vehicleor the like depending on the desired configuration. It is alsocontemplated that other attachment methods such as the use ofalternative fastening devices may be employed in addition to oralternative to the through-holes 140. For example, hook and loopfasteners, sewing, adhesives or other fastening devices or mechanismsmay be employed to locate the insert 10 relative to the seat cushion,the seat cover 142 or both.

While it is generally preferable that the layers 14, 16, 20 besubstantially coextensive with each other and that the rearward andforward layers 14, 20 form a substantially continuous seal or peripheralstrip 106 about the insert 10, it is contemplated that such is not thecase. Thus, it is contemplated that one or more of the layers 14, 16, 20may be less than coextensive with each other or non-existent. Forexample, the rearward layer 20 alone could provide a barrier sub-layer66 that provides a sufficient pathway for receiving air from theextension 139 and guiding air through the spacer layer to the seat cover142 or trim layers.

Operation

In operation, the insert of the present invention can preferably provideheating, cooling, ventilation or a combination thereof to an occupant ofa seat having the insert. In particular, if heat is desired, electriccurrent can be induced to travel through the heater sub-layer 26 by thecontrol unit 130 or otherwise such that the heater sub-layer 26 canprovide heat to the occupant.

Alternatively, if cooling or ventilation is desired, the blower can beoperated via the control unit 130 or otherwise to pull air through thethrough-holes 86 in the first layer 14 of the insert 10, through theopen space 58 of the middle layer 48 of the insert 10 and through thethrough-hole 98 of the rearward layer 20. Such air preferably flows atleast partially past the occupant of the seat and through the seat cover(e.g., a perforated leather seat cover or cloth seat cover) therebyproviding ventilation to the occupant and providing convective heattransfer from the occupant to the flowing air.

Although, it may be preferable for only the heater sub-layer 26 or theventilation system to be running at one time, it is contemplated thatboth may be operated simultaneously. Moreover, it is contemplated thatboth the heater sub-layer 26 and the ventilation system may be operatedat various levels (e.g., 2 or more levels of output) such as by having ablower that can operate at different levels or by having various levelsof electricity flowing thought the heater sub-layer 26. It is alsocontemplated that the blower may push air into the open space 58 of theinsert 10 as well as pulling air from the open space 58.

It is also contemplated that one or more temperature sensors (e.g., athermostat) may be included adjacent the insert, the trim layer or thelike. Preferably, any temperature sensors are near the seat cover or theinsert for sensing a temperature closely related to (e.g., at or near) atemperature being experienced by an individual in the seat. Suchtemperature sensors may be in signaling communication with the controlunit 130 such that the control unit 130 can control the blower 22, theheater layer 28 or both for attaining or maintaining a desiredtemperature at areas adjacent the individual and/or the temperaturesensor. Moreover, the control unit 130 may be programmed withinstructions for commanding the blower 22, the heater layer 28 or bothto change output levels (e.g., turn on or turn off) if the temperaturesensor senses a temperature above or below one or more threshold levels.An example of such programming is described in a copending patentapplication titled “AUTOMOTIVE VEHICLE SEATING COMFORT SYSTEM”, Ser. No.60/428,003, filed Nov. 21, 2002 and incorporated herein by reference forall purposes.

Advantageously, the plastic film sub-layers 28, 66 respectively of thefirst and third layers 14, 20 provide a substantially gas-tight sealabout the middle layer 16 (e.g., the spacer sub-layer 48). In thismanner, gas flow to and from the open space 58 of the spacer sub-layer48 is substantially restricted to flowing through the through-holes 86,98 of the first and third layers 14, 20.

In a highly preferred embodiment, the through-hole 98, which may bedefined by the sub-layers 66, 70 of the rearward layer 20 or by theattachment component 72, spans an area no greater than about 100 cm² orhigher, more preferably between about 15 cm² to about 60 cm², even morepreferably between about 25 cm² and about 40 cm² and most preferablybetween about 30 cm² and about 35 cm² depending upon the size of theblower. Advantageously, for maintaining more efficient flow of air, thethrough-holes 86 on the front layer 14 may be sized to span areas, thesum of which, is substantially similar (e.g., within 20 cm², morepreferably within 10 cm² and even more preferably within 5 cm²) to thearea of the through-hole 98 in the rearward sub-layer 20. Additionally,the open space 58 of the middle layer 58 may be sized such that nearlyany cross-section substantially perpendicular to airflow therethrough isalso substantially similar (e.g., within 20 cm², more preferably within10 cm² and even more preferably within 5 cm²) to the area of thethrough-hole 98 in the rearward sub-layer 20.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

1-40. (canceled)
 41. A method for manufacturing an insert for providingventilation of a seat, comprising the steps of: providing a firstpolymeric gas barrier layer having a plurality of openings for fluidlycommunicating with an air permeable seat cover, an intermediate layerincluding a spacer material, and a second polymeric gas barrier layerwherein either the first barrier layer or the second barrier layerincludes at least one opening for fluidly communicating with an airmover; and laminating the first and second barrier layers about aperipheral edge of the insert for defining a peripheral strip extendingabout the insert and for confining the spacer material within the firstand third layer so that the spacer material forms an open space withinthe insert wherein the spacer material remains at least partiallypliable or flexible between the first and the second layers.
 42. Themethod of claim 41 wherein the strip has a width between about 0.2 cmand about 3 cm.
 43. The method of claim 41 wherein the strip has a widthbetween about 1.0 cm and 2.0 cm
 44. The method of claim 41 wherein thelaminating step includes adhering the first and second layers togetherby an adhesive including a material selected from polyamides,polyesters, elastomers, urethanes, olefin polymers or a combinationthereof.
 45. The method of claim 41, further comprising a step ofattaching a heater to insert.
 46. The method of claim 45 wherein theattaching step includes laminating a heater layer to the first layer.47. The method of claim 46 wherein the heater layer includes a lay wireheater, a carbon fiber heater, a positive thermal coefficient (PTC)heater, or a thermoelectric heater.
 48. The method of claim 46 whereinthe heater layer includes thin and flat heater elements.
 49. The methodof claim 48 wherein the heater layer includes a positive thermalcoefficient (PTC) heater.
 50. The method of claim 41 further comprisinga step of forming an air permeable layer over the first barrier layer.51. The method of claim 41, further comprising a step of attaching theinsert to the air mover with an attachment component including a framemember defining an opening or through hole.
 52. A method formanufacturing an insert and providing ventilation of a seat of anautomotive vehicle, comprising the steps of providing a first polymericgas barrier layer having a plurality of openings, an intermediate layerincluding a spacer material and a second polymeric gas barrier layerwherein either the first barrier layer or the second barrier layerincludes at least one opening; laminating, by adhesion or melt seal, thefirst and second barrier layers about a peripheral edge of the insertfor defining a peripheral strip extending about the insert and forconfining the spacer material within the first and third layer so thatthe spacer material forms an open space within the insert wherein thespacer material remains at least partially pliable or flexible betweenthe first and the second layers; providing an air mover in fluidcommunication with the at least one opening; and placing the pluralityof openings in fluid communication with an air permeable seat cover of aseat of an automotive vehicle.
 53. The method of claim 52 furthercomprising a step of attaching a wire harness to the insert.
 54. Themethod of claim 52 wherein the resulting area of the plurality ofopenings in the first layer are within 20 cm² of the resulting area ofthe at least one opening.
 55. The method of claim 52 wherein theresulting area of any cross section of air space defined by the spacersubstantially perpendicular to air flow through the spacer is within 30cm² of the resulting area of the at least one opening in the thirdlayer.
 56. The method of claim 52 wherein the air mover is attached toan extension of the insert and the insert is free of any heater.
 57. Themethod claim 52 wherein the first and second layers are adhesivelybonded together with a hot melt adhesive.
 58. The method of claim 52wherein the air mover is adapted to pull air through the openings in thefirst layer and the open space.
 59. The method of claim 52, furthercomprising a heater layer wherein the spacer material is formed withrubber, foam, plastic or fibers and the heater layer includes a positivethermal coefficient (PTC) heater.
 60. A method for manufacturing aninsert and providing ventilation of a seat of an automotive vehicle,comprising the steps of providing a first polymeric gas barrier layerhaving a plurality of openings, an intermediate layer including a spacermaterial, and a second polymeric gas barrier layer wherein either thefirst barrier layer or the second barrier layer includes at least oneopening; adhering the intermediate layer to the first barrier layer, thesecond barrier layer or both; laminating a heater layer to the firstbarrier layer; laminating, by adhesion or melt seal, the first andsecond barrier layers about a peripheral edge of the insert for defininga peripheral strip extending about the insert and for confining thespacer material within the first and third layer so that the spacermaterial forms an open space within the insert wherein the spacermaterial remains at least partially pliable or flexible between thefirst and the second layers; providing an air mover in fluidcommunication with the at least one opening; and placing the pluralityof opening in fluid communication with an air permeable seat cover of aseat of an automotive vehicle.
 61. The method of claim 60, wherein: i.the spacer is formed of a polymeric strand material confined betweenopposing fabric panels; ii. providing the air mover in fluidcommunication includes attaching the air mover to the insert with a snapfit; and iii. wherein the strip is between about 1.0 cm and 2.0 cm. 62.The method of claim 61 further comprising: i. providing a control unitprogrammed with instructions for commanding the air mover, means forseat heating or both to change output levels if a temperature sensorsenses a temperature above or below one or more threshold levels; andii. forming a tape pocket and securing a wire harness to the insertwithin the tape pocket; wherein: i. the gas barrier layer is formed ofclosed pore foam; ii. the insert is formed with a gauze, a cloth orfleece outer layer; iii. the air mover is adapted to blow air throughthe openings in the first layer and the open space; iv. the first layerand the second layer are formed of a film having a thickness of 0.1 mmto 2.0 mm; and v. the first and second layers are formed with throughholes that are sealed.